How To Cut Out A Door Hinge With A Dremel (Quickly & Easily!)

Nick Durante
by Nick Durante

You can use a Dremel to carve wood, sand surfaces, sharpen a chainsaw, and cut out a door hinge. A Dremel tool is a must-have for any DIY builder-owner, and they come in handy when installing doors. It’s clear that a Dremel is a useful tool, but how can it help you cut out a door hinge?

First, mark the placement of the top hinge 6” down from the top, and the bottom hinge 9” up from the bottom. Mark them with tape, then trace into it with a utility knife before you put a 650 router bit on your Dremel. Measure the depth of the door, set your Dremel to the right height, and cut into the tracing that you did.

After that, all that you need to do is screw the hinges into place with a drill or screwdriver. A door is nothing without well-cut hinges, and it can make or break the installation.

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How To Cut Out a Door Hinge With a Dremel

Follow along as we explore how to cut out a door hinge with a Dremel.

Tools Check List

You need to gather the proper materials before you can cut out a door hinge with a Dremel. It’s a simple process, but it does require that you be precise and have everything on hand. The most essential items that you need to cut out a door hinge with a Dremel include:

  • A screwdriver
  • Drill (optional)
  • Door hinges
  • Measuring tape
  • Utility knife
  • Screws
  • Dremel
  • Dustpan
  • Safety goggles
  • 650 router bit

You can choose a drill over a screwdriver, but either tool will work when you screw in the hinges. Obtain a 650 router bit so that you can cut out the door hinges with precision and power. Use the measuring tape and a utility knife to measure and mark precisely where you want the hinges to go.

The safety goggles are essential so that you don’t damage your eyes when sawdust and debris enter the air. If you have a dustpan on hand, it will be helpful for the cleanup when you finish the project. Finally, you will need a pair of door hinges, and most of them come with a set of screws.

Step 1. Mark the Door

You will have a hard time cutting out the door hinge unless you carefully and precisely mark the door. Position the door against the doorway so that you can line up where you’d like the hinges to go. Identify the spot that best fits your door and mark a spot for each hinge that you can refer to later.

Another way to do this is to set the door down on its side and break out your measuring tape. Measure 6” down from the top of the door and place tape as straight as you can. Similar to measuring a pre-hung door, you start from the top and work your way to the bottom.

You can draw a line along the tape when you mark the top hinge so that you have a backup measurement. Now, measure 9” up from the bottom and mark it with tape, then trace the tape with a pencil.

Step 2. Trace the Hinges

Once you’ve marked where you want to place the hinges, you must trace the hinges themselves. Set the door down flat on the ground, grab your first hinge, and line it up with the tape marking. Place the hinge straight along the edge of the door folded like it would when it is installed.

You want to make sure that the hinge will act as a proper axis for when you open and close it. Set the hinge in the proper and even position, and carefully trace the outline on each side with a utility knife. Make sure that the utility knife cuts as close to the hinge as possible so that you have an exact tracing to cut later.

Repeat this 1-2 more times for the top hinge so that the tracing is noticeable and distinct. Now, place the bottom hinge in the same way and trace it with a utility knife as you did with the first one. Whether it takes two or three passes, you will be fine as long as you can see the marking.

Step 3. Set Up Dremel

You will need to change the bit on your Dremel before you can cut a door hinge with it. The 650 router bit is what you should use to cut a door hinge, but any straight bit should be fine. First, open the spindle, and simply attach the bit head of your choice by carefully inserting it.

Make sure to tighten the spindle once the straight-bit router is attached to the Dremel. Measure the door hinge one more time to make sure that you have the correct cutting depth. Now, adjust the cutting height on your Dremel so that it matches the depth of the door.

Step 4. Cut the Hinges

Now it’s time that you put on your safety glasses or goggles as this next step will stir up debris. Carefully line up your Dremel’s router bit with the line that you traced with the utility knife. This step is easier with another set of eyes to make sure that you are totally in line and even.

When you are ready, turn on the Dremel and slowly press it down onto your traced measurement. Go over each edge that you traced while maintaining light pressure on the Dremel until all of the wood is removed. Have a dustpan nearby and ready as sawdust and debris fly around the room that you do it in.

After you’ve cut through the lines, clean up, and grab your door hinge to compare it to. Carefully place the door hinge on the now-cut door, and it should fit perfectly. Repeat the process with your bottom hinge and check to make sure it fits before the next step.

Step 5. Install Hinges

You can install the hinges now if they are a perfect fit for what you cut into the door. Otherwise, you can continue to cut with the Dremel until they do fit but be careful not to get carried away. Enlist the help of a friend or family member to help you keep the door vertical while you screw the door hinges in place.

You can either use a screwdriver or a drill to screw the hinges into place, but a drill or electric screwdriver is quicker. Door hinges generally come with a set of screws, but if not, you’ll need to go by them. It’s easiest to start with the screw in the middle so that you don’t need to press your hand against the hinge the whole time.

Secure each screw into place, and then carefully repeat the process for the bottom hinge. Now, you can test out the door by carefully moving and checking to see if it moves well. All that’s left to do is clean up any debris or sawdust that might be laying around, and you’re done!

Related Questions

Can you cut glass with a Dremel?

Yes, you can cut glass with a Dremel, but you have to use bits such as the 545 Diamond Wheel or 663DR glass drill it.  You can still damage and crack glass when you use a Dremel even if you use the proper bit attachment. The key is to run the glass below water before cutting and apply as little pressure as possible with the Dremel.

Can you Dremel acrylic?

A Dremel can easily cut through acrylic, and it’s considered one of the best tools for doing so. The best attachment for using a Dremel on acrylic is a 561 bit, but you can damage it if you go too quickly. Be sure to set your speed to 6, and try not to exceed a speed of 8, and you can Dremel acrylic.

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Summing It Up

You can easily cut out a door hinge with a Dremel if you take the proper measurements before you start. Use measuring tape 6” from the top, and 9” from the bottom, and place tape on the door to mark the exact spots. Go over the edges of the tape with a utility knife to make it easy for you to go over with the Dremel later.

Change out the bit on your Dremel for a 650 router bit, or any straight bit that you like to use. Place the hinges on the door before you cut into it to make sure that there is a good fit. Now, measure the depth of the door so that you know what to adjust your cutting height to.

You can cut into the door following the marks of the tape and your utility knife for each hinge. Once the wood is all cut out, you can place the hinges on the door to make sure that they’re a perfect match. All that’s left to do is screw the hinges in, and you’ve successfully cut out a door hinge with a Dremel.

Nick Durante
Nick Durante

Nick Durante is a professional writer with a primary focus on home improvement. When he is not writing about home improvement or taking on projects around the house, he likes to read and create art. He is always looking towards the newest trends in home improvement.

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